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Flexmaster
Economical production of tubes Single station welder
for the highest flexibility
Machinery and equipment for innovative forming,
cutting and joining systems
A brand of weil engineering gmbh
weil technology
Shape.Join.
Look ahead.
weil technology
weil engineering gmbhHeadquarters Müllheim
Plant 1
weil technology is a weil enginee-ring gmbh brand and incorporates different enterprises, which are mar-ket and technology leaders in the field of sheet metal processing. Ma-chines and systems for innovative forming, cutting and joining tech-niques have been designed and ma-nufactured for the global market within the group since 1987.
Our turn-key and fully automated production lines are primarily found in the automotive sector and in the HVAC, housing and container con-struction and electrical industries. Each company within weil techno-logy focuses on its core competency and together we are able to offer our clients a large pallet of customized system solutions. Our focus is on flexible, rational and efficient production while making use of innovative roll-forming, stam-ping, laser welding and laser cutting technologies.
weil technology clients value the fact that our system concepts are ef-ficient, reliable and consistently re-produce high quality parts: Shape. Join. Look ahead.
2 Shape. Join. Look ahead.
weil technology
Automatic joining of tube edges is our specialty
The art of joining
The Flexmaster series has been the most reliable longitudinal seam welder for tubes and profiles, with the most diverse dimensions, on the market for many years.
The fully automatic clamping process guarantees the shortest cycle times and consistently opti-mal welding results.
Automatic aligning and joining of the welding edges and rapid changeover times with automatic diameter changes are trademarks of the Flexmaster series.
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weil technology
Flexmaster:Offers the highest quality in short tube welding
The Flexmaster series, one of the most successful machines within the group of longitudinal tube welders offered by weil technology, introduces a new machine to its ranks.We offer weil technology quality, short cycle times and optimal welding results, all at a very attractive price.Like all weil technology machines, the Flexmaster also includes automatic changeovers for diameter changes.
After selecting one of the programmes in the memory, the clamping tool automatically adapts to the new clamping position and the corresponding welding parameters are activated.
The machine is manually loaded and unloaded.
Your first step in tube production
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weil technology
Unbeatable when it comes to flexibility in geometry, diameter or tube lengths
Simple operability paired with reliability, automatic loa-ding and unloading up to unmanned production – the Flexmaster will stand up to all of your requirements.
Round or oval geometries are no problem with the paten-ted Flexmaster clamping concept.
This easy-to-operate and compact tube production unit can manufacture different diameters alternately without sacrificing productivity, all within a minimal footprint.
The „Champion“
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weil technology
The „Big One“
Solutions for large tube diameters with all the advantages of the Flexmaster Series
To cover diameter ranges up to 1000 mm (39”), the Flex-master 1000 is equipped with a loading trolley which can position tube bodies up to a length of 2000 mm (78”) for welding.
Technical data Flexmaster 1000/2000
Operating range 200 - 1000 mm (8” – 40”)
Tube length 500 - 2000 mm (20” – 78”)
Material thickness 0.6 – 1.5 mm (0.024” – 0.059”)
Material* mild steel, stainless steel*
Welding sources Laser, TIG, Plasma
Cycle time ~ 60 s (laser welding)
*feasibility with special materials after verification of process
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weil technology
Single units interlinked for flexible productionAt the push of a button: high quality, short cycle times, flexible production.
Single production, multiple produc-tion with twin welding stations or continuous welding: the Flexmaster can be integrated into an interlinked manufacturing line for the highest productivity possible. Time is money. To make maximum use of its operati-on range, the welder can clamp and weld several tubes at once in one production cycle.
From Blank to Tube
1. Pallet2. Destacker3. Infeed table4. Roll-forming unit5. Transfer system6. Flexmaster7. Deposit table
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weil technology
Blanks stacked on an stationary pallet or a rotary pallet-changer are moved to the infeed table of the rollforming machine by a destacker.A servo-driven transport system unloads the roll-forming machine and pushes the non-welded tube into the Flexmaster. After welding, an unloading unit on the back of the machine removes the tube and drops it on a conveyor belt.
Roll-forming and tube welding machines in a fully automated process
Flexmaster as Part of the Manufacturing Line
1. Destacker2. Pallet table3. Infeed table4. Roll-forming machine5. Transfer unit6. Flexmaster7. Unloading unit8. Conveyor belt
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weil technology
Quality
Your advantages are high quality components and increased profitability
When evaluating the finished tube we do not only eva-luate the quality of the weld seam but the total process chain from material to cutting, roll-forming, clamping and welding.
Visual analysis of the weld seam gives a very good picture of seam irregularities, penetration, holes, undercut, seam width, discoloration and spots.
Testing by expanding the tubes to the final dimensions and cone tests show the high strength of the weld seams. This is the basis for high quality parts.1. Destacker
2. Pallet table3. Infeed table4. Roll-forming machine5. Transfer unit6. Flexmaster7. Unloading unit8. Conveyor belt
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weil technology
Flexmaster Series
Flexmaster 400/1250 Flexmaster 400/2000 Flexmaster 600/1500 D Flexmaster 1000/2000
Tube diameter 76 - 400 (600) mm (2.9“ - 15.7“ (23.62“))
76 - 400 (600) mm (2.9“ - 15.7“ (23.62“)
100 - 600 mm(3.93“ - 23.62“)
200 - 1000 mm (8” – 40”)
Tube length 100 - 1270 (1525) mm (3.93“ - 50“ (60“))
100 - 2000 mm(3.93“ - 78.74“)
200 - 1525 mm(7.87“ - 60“)
500 - 2000 mm (20” – 78”)
Material thickness 0.4 - 2.0 mm (0.015” – 0.078”)
0.8 - 3.0 mm(0.031” – 0.012”)
0.4 - 2.0 mm(0.015” – 0.078”)
0.6 – 1.5 mm (0.024” – 0.059”)
Materials mild steel, stainless steel
Welding sources Laser, TIG, Plasma Laser, TIG, Plasma Laser, TIG, Plasma Laser, TIG, Plasma
Output Up to 150 Tubes/h Up to 180 Tubes/h Up to 60 Tubes/h
*Other materials on request.
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weil technology
Service
Machines do not take notice of deadlines or production schedules and we realize that production downtimes are frustrating and unprofitable. Our service technicians understand the consequences of production downtimes and are on-call to assist you when and where necessary.
Not only are our machines custom made; our service support is also tailored to our clients needs. Clients choose from various service modules, which are then packaged together into individual service support packages.
HotlineOur clients have the opportunity to make use of our extended telephone hotline, which is available outside our office hours (Monday to Friday from 7:00 to 16:30). The hotline is available weekdays until 22:00 CET, excluding public holidays.
TeleserviceOur remote access capability allows our technicians to react quickly to our client’s needs by logging into their system to diagnose problems and implement solutions. Based on our many years of experience, this not only significantly reduces the need for on-site service visits, but also ensures that production downtimes are kept to a minimum. This enables our clients to save time, resources and money.
TrainingWe offer a comprehensive training programme, which can be customised for your individual needs and to suit any budget.
Preventative MaintenancePreventative maintenance has proven itself an important component of our service offering over the years, because it reduces the cost of repairs on site drastically, while increasing the productivity of machines.
Product Development SupportOur competent specialists are available to assist you with any product development or quality problems or questions.
Spare PartsYour spare parts will be delivered as quickly and cost effectively as possible.
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weil technology
Protected by U.S. Patents: Apparatus for manufacturing tubes US 7,293,687 B2 - Nov. 13, 2007 Continuous welding machine for welding a pipe blank US 2008/0257938 A1 - Oct. 23, 2008Roll-forming or bending machine US 7,536,891 B2 - May 26, 2009
weil engineering gmbh
Neuenburger Str. 2379379 MüllheimGermany
+49 7631 1809-0 Phone+49 7631 1809-149 Fax
[email protected] www.weil-engineering.de
Weil EngineeringNorth America LLC
25909 Meadowbrook Road Novi, MI 48375 USA
+1 248 344 2211 Phone+1 248 344 2220 Fax
SCHAAL engineering GmbH
Postweg 2773084 Salach Germany
+49 7162 9607-0 Phone +49 7162 9607-77 Fax
Weil Machinery (Shanghai) Co., Ltd.
10th Floor, Room 1003No. 381 Huaihai Zhong RoadHuangpu District200020 Shanghai
+ 86 21 6391 5865 Phone+ 86 21 6391 5869 Fax+ 86 158 0177 6073 Mobile
weil engineering gmbh Muellheim Plant 2
A brand of weil engineering gmbh
weil technology
